Upright vacuum cleaner with cyclonic air flow

ABSTRACT

An upright vacuum cleaner (A) includes an upright housing section (B) and a nozzle section (C). A cyclonic airflow dirt and dust separating chamber (54) is defined in said upright housing section. A suction source (E) pulls air and entrained dirt, dust, and other contaminants through a main suction opening (26) formed in the underside (24) of the nozzle and into the cyclonic airflow chamber (54). The cyclonic airflow chamber causes the suction airstream to travel in a cyclonic path such that the entrained contaminants are separated therefrom and deposited into a dirt container (52) that defines the chamber (54). A main filter element (K) filters residual contaminants from the suction airstream between the chamber and the suction source. The main filter element is preferably made from high-density polyethylene porous filter media. A final filter assembly (F) filters the suction airstream discharged by the suction source to ensure that the air discharged into the atmosphere is contaminant free, including those contaminants introduced into the airstream by the suction source itself.

This application is a continuation-in-part of application Ser. No.09/122,541 filed on Jul. 24, 1998 and still pending. That applicationis, in turn, a continuation-in-part of application Ser. No. 09/004,999filed Jan. 9, 1998 and still pending.

BACKGROUND OF THE INVENTION

The present invention relates to vacuum cleaners. More particularly, thepresent invention relates to upright vacuum cleaners used for suctioningdirt and debris from carpets and floors.

Upright vacuum cleaners are well known in the art. The two major typesof these vacuum cleaners are a soft bag vacuum cleaner and a hard shellvacuum cleaner. In the hard shell vacuum cleaner, a vacuum sourcegenerates the suction required to pull dirt from the carpet or floorbeing vacuumed through a suction opening and into a filter bag housedwithin the hard shell upper portion of the vacuum cleaner.

To avoid the need for vacuum filter bags, and the associated expense andinconvenience of replacing the bag, another type of upright vacuumcleaner utilizes cyclonic air flow, rather than a filter bag, toseparate the majority of the dirt and other particulates from thesuction air stream. The air is then filtered to remove residualparticulates, returned to the motor and exhausted.

For many of the prior art cyclonic air flow vacuum cleaners, the processof emptying the dirt collection container has been found inconvenientand often resulted in the spillage of the cup contents. Also, thereplacement of filter elements in these units has not been convenient.

In some cyclonic air flow vacuum cleaners, the exhaust air is not freeof residual contaminants. Because the cyclonic action of suchconventional cyclonic vacuum cleaners does not completely remove alldust, dirt and other contaminants from the suction air stream, it isnecessary to include a filter downstream from the cyclonic chamber.However, the conventional filter elements so used have causedconsiderable difficulty. A conventional filter which is sufficientlyfine to filter the air stream effectively, unduly restricts air flow anddecreases the effectiveness of the cyclonic action. On the other hand, acoarse filter does not effectively filter the air stream of residualcontaminants. Furthermore, conventional filter media, such as paper orfibrous media, has been found to clog readily thereby unduly decreasingair flow rates over time.

Accordingly, it has been deemed desirable to develop a new and improvedupright vacuum cleaner having a cyclonic air flow which would overcomethe foregoing difficulties and others while providing better and moreadvantageous overall results.

SUMMARY OF THE INVENTION

According to the present invention, a new and improved upright vacuumcleaner is provided.

In accordance with the first aspect of this invention, a vacuum cleanerincludes a housing defining a cyclonic air flow chamber for separatingcontaminants from a suction air stream. The housing includes an inletfor the chamber and an outlet for the chamber. The suction air streaminlet and outlet are both in fluid communication with the cyclonic airflow chamber. A suction opening is defined on the housing. The suctionopening is fluidically connected with the cyclonic air flow chamberinlet. An air stream suction source is located on the housing. Thesuction source has an inlet fluidically connected to the cyclonicchamber outlet and a suction source outlet. The suction sourceselectively establishes and maintains a suction air stream from thesuction opening to the suction source outlet. A main filter supportextends upwardly from the floor of the housing for releasably securing amain filter element centrally in the cyclonic air flow chamber. A mainfilter element is secured thereto. A dirt cup is selectively positionedin the housing with the main filter element being located in the dirtcup.

One advantage of the present invention is the provision of a new andimproved vacuum cleaner.

Another advantage of the invention is found in the provision of thevacuum cleaner with a cyclonic air flow chamber through which thesuction air stream flows for separating dust and dirt from the airstream and for depositing the separated dust and dirt into an easily andconveniently emptied dirt cup.

Still another advantage of the present invention resides in theprovision of a cyclonic air flow upright vacuum cleaner with a mainfilter that effectively filters residual contaminants from the suctionair stream between the cyclonic air flow chamber and the motor assemblywithout unduly restricting air flow and without premature clogging.

Yet another advantage of the present invention is the provision of acyclonic air flow upright vacuum cleaner in which a direct air path isprovided between a suction air flow inlet, a suction air flow outlet anda vacuum source preferably positioned directly beneath the suction airflow outlet.

Still yet another advantage of the present invention is the provision ofa cyclonic air flow upright vacuum cleaner with a final filter locateddownstream from the suction motor assembly for filtering the suction airstream immediately prior to its exhaustion into the atmosphere.

A further advantage of the present invention is the provision of avacuum cleaner with a tangential dirty air inlet into a dust separationchamber and an axial clean air outlet from the dust separation chamber,wherein the outlet is separated from the inlet by a filter. Preferably,the dirty air inlet is located at an upper end of the dust separationchamber and the outlet is located at a lower end thereof.

A yet further advantage of the present invention is the provision of avacuum cleaner with a cyclonic air flow chamber wherein accummulateddust and dirt in the chamber serve as a filter means for furtherfiltering at least a portion of the suction air stream passing throughthe chamber.

A yet further advantage of the present invention is the provision of avacuum cleaner with a cyclonic air flow chamber and a main filterelement wherein the main filter element is positioned in a removabledirt cup at least partially defining the cyclonic air flow chamber forease of emptying the dirt cup and for cleaning the filter.

Still other benefits and advantages of the invention will becomeapparent to those of average skill in the art upon a reading andunderstanding of the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may take form in certain components and structures,preferred embodiments of which will be illustrated in the accompanyingdrawings wherein:

FIG. 1 is a perspective view illustrating a cyclonic air flow uprightvacuum cleaner in accordance with a first embodiment of the presentinvention;

FIG. 2 is a front elevational view of the vacuum cleaner illustrated inFIG. 1;

FIG. 3 is a right side elevational view of the vacuum cleaner of FIG. 1;

FIG. 4 is an enlarged right side elevational view in cross section ofthe vacuum cleaner of FIG. 1 showing air flow through the cyclonic airflow dust and dirt separating chamber;

FIG. 5 is an exploded perspective view of a dust cup cylinder, filterrack and filter employed in the vacuum cleaner of FIG. 4;

FIG. 6 is a schematic view of a cyclonic air flow dust and dirtseparating chamber and adjacent components of a vacuum cleaner accordingto a second preferred embodiment of the present invention;

FIG. 7 is an exploded schematic perspective view of a dust cup cylinder,filter rack and filter employed in the vacuum cleaner of FIG. 6;

FIG. 8 is an assembled schematic perspective view of the dust cup,filter rack and filter of FIG. 7 with a lid spaced away therefrom; and,

FIG. 9 is a greatly enlarged side elevational schematic view of a motorand seal interface for the vacuum cleaner of FIG. 6.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the FIGURES, wherein the showings are for purposes ofillustrating preferred embodiments of the invention only and not forpurposes of limiting the same, FIGS. 1-5 illustrate an upright vacuumcleaner A including an upright housing section B and a nozzle basesection C. The sections B,C are pivotally or hingedly connected throughthe use of trunnions or another suitable hinge assembly D so that theupright housing section B pivots between a generally vertical storageposition (as shown) and an inclined use position. Both the upright andnozzle sections B,C are preferably made from conventional materials suchas molded plastics and the like. The upright section B includes a handle20 extending upward therefrom by which an operator of the vacuum A isable to grasp and maneuver the vacuum.

During vacuuming operations, the nozzle base C travels across the floor,carpet, or other subjacent surface being cleaned. With reference now toFIG. 4, an underside 24 of the nozzle base includes a main suctionopening 26 formed therein which extends substantially across the widthof the nozzle at the front end thereof. As is known, the main suctionopening 26 is in fluid communication with the vacuum upright bodysection B through a passage and a connector hose assembly 34 (FIG. 3). Arotating brush assembly 36 is positioned in the region of the nozzlemain suction opening 26 for contacting and scrubbing the surface beingvacuumed to loosen embedded dirt and dust. A plurality of wheels 38support the nozzle on the surface being cleaned and facilitate itsmovement thereacross.

The upright vacuum cleaner A includes a vacuum or suction source forgenerating the required suction airflow for cleaning operations. Asuitable suction source, such as an electric motor and fan assembly E,generates a suction force in a suction inlet and an exhaust force in anexhaust outlet. The motor assembly airflow exhaust outlet is in fluidcommunication with a final filter assembly F (FIG. 2) for filtering theexhaust airstream of any contaminants which may have been picked up inthe motor assembly immediately prior to its discharge into theatmosphere. The motor assembly suction inlet, on the other hand, is influid communication with a cyclonic suction airflow dust and dirtseparating region G of the vacuum A to generate a suction force therein.

The cyclonic suction air flow dust and dirt separating region G housedin the upright section B includes a cyclonic airflow chamber 54 definedby an upper fixed housing member 50a and a lower dirt cup or container52 which is pivotally and releasably connected to the upper housing B ofthe vacuum cleaner.

The suction airstream enters an upper portion of the cylconic dust anddirt separation chamber 54 through a generally tangential suctionairstream inlet which is formed in the upper section 50a of the mainfilter housing assembly 50. The suction airstream inlet of the chamber54 is in fluid communication with a suction airstream hose 82 through afitting 84 as illustrated in FIG. 2.

With reference now to FIG. 1, the dirt container 52 is connected to thevacuum cleaner upright section B through the use of a hinge assembly 90which allows the dirt container to pivot between an operative uprightposition and an open forwardly tilted position. A handle 96 is providedon an exterior of the container 52 to facilitate operator movement ofthe container between the operative, open, and removed positions. Alatch 98 (FIG. 2) retains the dirt container in the operative position.The latch 98 is biased through the use of a spring or other resilientmember or via the natural resiliency of the plastic from which it ismolded. The dirt container has an upper edge 100 defining an upper openend of the container. This end is preferably inclined downwardly in adirection away from the handle 20. This edge mates with the adjoiningedge 102 of the upper housing member.

The dirt cup 52 includes a main filter support, such as a post, stem orlike structure 150 extending upwardly from a floor or base 152 thereof.The post 150 is positioned in a central region of a cyclonic airflowchamber 154. A hollow cylindrical main filter element K is positionedover the main filter support 150.

With reference now to FIG. 5, the filter element K is engaged in aninterference fit with vanes 154 and a disk-like plateau 156 located onthe floor 152 of the filter support so that the filter is releasably yetsecurely retained in its operative position, even when the dirt cup 52is removed from the vacuum cleaner and inverted for purposes of emptyingthe contents thereof. A filter locking means 158 accommodating a gasket159 is provided along the uppermost edge of the main filter element K.The main filter element K extends upwardly from the dirt cup floor 152to a level approximately equal to an upper edge 100 of the dirt cup.Most preferably, as shown herein, the upper edge of the main filterelement K is also sloped in the same manner as is the dirt cup upperedge 100. Over the entire height of the dirt cup 52, an annular cyclonicairflow passage is defined between the main filter K and the dirt cup52. The base 152 serves also as the base of the dirt cup 52. To thisend, the base 152 is suitably secured by conventional means to the sidewalls forming the dirt cup.

The filter element K preferably comprises POREX brand, high densitypolyethylene-based, open-celled, porous media available commerciallyfrom Porex Technologies Corp. of Fairburn, Ga. 30212, or an equivalentforaminous filter media. This preferred filter media is a rigidopen-celled foam that is moldable, machinable, and otherwise workableinto any shape as deemed advantageous for a particular application. Thepreferred filter media has an average pore size in the range of 45 μm to90 μm. It can have a substantially cylindrical configuration as isillustrated in FIG. 5, or any other suitable desired configuration. Thefilter element could also have a convoluted outer surface to provide alarger filtering area. Some filtration is also performed by the dirt inthe bottom end of the dirt cup in the dirt L as shown by the arrow M.

With reference now to FIG. 6, a cyclonic suction airflow dust and dirtseparating region M according to a second preferred embodiment of thepresent invention is there illustrated. This embodiment includes a dustand dirt cup or container 202. The container has a substantially closedlower end 204 having a centrally positioned aperture 205 therein and anopen upper end 206. A lid 208 (FIG. 8) can be selectively placed on thecontainer or dirt cup.

Disposed within the dirt cup 202 is a filter and rack assembly 210.Defined between an inner wall of the dirt cup 202 and the filter andrack assembly 210 is a cyclonic chamber 212 which communicates with asuction inlet passage 214 extending into an upper end of the cyclonicairflow chamber 212. The inlet opening is oriented tangential to thecyclonic chamber 212 so as to encourage a cyclonic airflow.

With reference now to FIG. 7, the filter and rack assembly includes afilter rack 220 having three vanes 222 which radiate away from eachother like the spokes on a wheel. In other words, the vane assembly isY-shaped in cross section. The filter rack is mounted on a base 224.Located at the bottom end of the base are three openings 226 which areseparated from each other by the vanes 222 and extend only as farradially outwardly from a center point of the base 224 as is the lengthof each vane 222. A filter element 230 is supported on the filter rack.The filter element is a hollow member having an open lower end 232 whichallows access to a hollow interior 234 of the filter. However, thefilter can have a closed top end 236.

The interior 234 of the filter 230 is so sized as to allow the filter tobe slipped over the vanes 222. The open lower end 232 of the filter thusis seated on the plate 224. However, the hollow interior 234 of thefilter is in communication with the several openings 226 extendingthrough the filter rack base 224. The filter rack base is preferablysecured by conventional means to the open lower end 204 of the dirt cupcylinder 202 to close same. The upper end 206 of the dirt cup remainsopen.

With reference now also to FIG. 9, positioned beneath a bottom face 240of the dirt cup 202 is an elastomer ring seal 242 which has a centralaperture 244 extending therethrough. The seal 242 is seated around theopenings 226 of the filter rack base 224. A dirt cup support wall 245 ofa housing of the vacuum cleaner contains a central opening 246 which isaligned with the aperture 244. An enlarged diameter section 248 isdisposed on an upper face of the wall 245. Adapted to be housed in theopening is a post filter element 249. The post filter 249 can be madefrom a suitable conventional open cell foam plastic material, if sodesired. The support wall 245 is meant to sit on a motor support wall250 for mounting a suction motor N. The motor support has a centrallylocated bore 252 extending therethrough. The bore also includes anenlarged diameter section 254 defined on its lower face. A motor seal256 has a reduced diameter upper end 258 which is accommodated in theenlarged diameter lower end 254 of the motor support 250. A centrallylocated bore 260 extends through the motor seal. In this embodiment, themotor and fan assembly N is positioned directly beneath the motor seal256.

As is evident from FIG. 6, an in-line flow path is thus provided fromthe dust inlet 214 through the motor and fan assembly N. Morespecifically, dirty air flows into the dust inlet 214 and thus into thecyclonic chamber 212 defined within the dirt cup 202. As illustrated bythe arrow 260 the airflow into the chamber 212 is tangential. Thiscauses a vortex-type flow as is illustrated by arrows 262. Such vortexflow is directed downwardly in the dust chamber 212 since the top endthereof is blocked by the lid 208. The air flows radially inwardly andthrough the filter 230. The air then flows axially downwardly throughthe hollow interior of the filter 230 as illustrated by arrow 264.Subsequently, the air flows through the support wall opening 246, themotor support opening 252 and into and through the suction motor and fanassembly N as is illustrated by arrow 266. After being exhausted fromthe motor and fan assembly, the air flows through a conduit 270 definedin the upright housing section of the vacuum cleaner and into a plenum272 which holds an output filter 274. This is illustrated schematicallyby the arrows 276 and 278 in FIG. 6.

Suction airflow from the cyclonic chamber 212 is not able to bypass themain filter element 230, but instead must pass therethrough and befiltered of residual contaminants due to the existence of the seal 242.However, should there be some reason why there is a leak between thefilter 230 and the filter rack base 224, the post filter 249 (FIG. 9)will prevent dirt from being sucked directly into the motor and fanassembly N.

The conduit 270 is itself in fluid communication with the elongatedplenum 272 that opens to the atmosphere and houses filter media 274. Aprotective grid or grate structure is snap-fit or otherwise effectivelysecured over the plenum 272 to secure the filter media in place. Thefilter media is preferably a high efficiency particulate arrest (HEPA)filter element in a sheet or block form. Those skilled in the art willrecognize that even if the motor/fan assembly N causes contaminants tobe introduced into the suction airstream downstream from the main filterelement, the final filter assembly P will remove the same such that onlycontaminant-free air is discharged into the atmosphere.

The location of the inlet 214, the outlet 216, and the generallycylindrical configuration of the cyclonic airflow chamber 212 causes thesuction airstream to follow a swirling or cyclonic path downward withinthe chamber 212 and then radially inward through the filter 230 to movedownwardly through the inside of the centrally located main filter 230.The orientation of the inlet 214 will affect the direction of cyclonicairflow, and the invention is not meant to be limited to a particulardirection, i.e, clockwise or counterclockwise.

Those skilled in the art will certainly recognize that the term"cyclonic" as used herein is not meant to be limited to a particulardirection of airflow rotation. This cyclonic action separates asubstantial portion of the entrained dust and dirt from the suctionairstream and causes the dust and dirt to be deposited in the dirt cupor container 202. The suction airstream then passes through the mainfilter element 230 so that residual contaminants are removed, and exitsthe cyclonic chamber 212 through the aperture 244 in the seal 242 andthrough the aperture 246 formed in the dirt cup support wall 245. Thesuction airstream is communicated to the motor/fan assembly N andexhausted through conduit 270 to the final filter assembly P where it isfiltered again by the HEPA filter 274 to remove any contaminants thatmay have passed through the filter 230, and any contaminants in theairstream due to its passage through the motor/fan assembly N.

The main filter element 230 can be cleaned by washing it, eithermanually or in a dishwasher--since it is dishwasher-safe--to remove dustor dirt particles adhering to the filter element. It is, however,important that the filter 230 be dried before it is used again. Thefinal filter media of the filter assembly 274, however, can not becleaned and must be replaced when it becomes clogged.

The invention has been described with reference to the preferredembodiments. Obviously, modifications and alterations will occur toothers upon reading and understanding the preceding detaileddescription. It is intended that the invention be construed as includingall such modifications and alterations insofar as they come within thescope of the appended claims or the equivalents thereof.

Having thus described the preferred embodiments, the invention is nowclaimed to be:
 1. A vacuum cleaner comprising:a housing defining acyclonic airflow chamber for separating contaminants from a suctionairstream, said housing further comprising an inlet for said cyclonicairflow chamber and an outlet for said cyclonic airflow chamber; a dirtcontainer selectively mounted in said housing for receiving andretaining dirt and dust separated from said suction airstream; a nozzlebase including a main suction opening, said main suction opening beingfluidically connected with said cyclonic airflow chamber inlet; anairstream suction source having an inlet disposed adjacent said cyclonicairflow chamber outlet and a suction source exhaust outlet spaced fromsaid cyclonic airflow chamber, said suction source selectivelyestablishing and maintaining an approximately linear suction airstreamfrom said outlet of said cyclonic airflow chamber to said inlet of saidairstream suction source; and, a main filter assembly positioned betweensaid cyclonic airflow chamber and said suction source for filteringcontaminants from said suction airstream.
 2. The vacuum cleaner as setforth in claim 1 wherein said main filter assembly comprises a filterelement including a high-density polyethylene porous filter media whichincludes pores having an average pore size of approximately 45 μm toapproximately 90 μm.
 3. The vacuum cleaner as set forth in claim 1wherein said filter element is approximately cylindrical in shape. 4.The vacuum cleaner as set forth in claim 3 wherein said filter elementhas a convoluted outer surface.
 5. The vacuum cleaner as set forth inclaim 1 wherein said cyclonic airflow chamber inlet is disposedtangentially adjacent an outer periphery of said cyclonic airflowchamber and said cyclonic airflow chamber outlet is parallel to alongitudinal axis of said cyclonic airflow chamber.
 6. The vacuumcleaner as set forth in claim 1 further comprising a final filterassembly positioned on one of said housing and said nozzle base, saidfinal filter assembly being in fluid communication with said suctionsource exhaust outlet for filtering said suction airstream exhaustedfrom said suction source into the atmosphere.
 7. The vacuum cleaner asset forth in claim 6 wherein said final filter assembly comprises a highefficiency particulate arrest (HEPA) filter media.
 8. The vacuum cleaneras set forth in claim 1 wherein said dirt container is pivotable betweenan operative position and an open position, and said dirt containerincludes an open upper end defined by an inclined edge such that whensaid dirt container is pivoted fully into the open position, theinclined edge is located in a substantially horizontal plane to inhibitspillage of the separated dirt and dust.
 9. An upright vacuum cleanercomprising:an upright housing section including a handle; a nozzle basesection hingedly interconnected with the upright housing section, saidnozzle base section including a main suction opening formed in anunderside thereof; a cyclonic airflow chamber defined in said uprighthousing section for separating dust and dirt from a suction airstream,said cyclonic airflow chamber including an air inlet and air outlet; asuction source located in one of said upright housing section and saidnozzle base section and having a suction airflow inlet in fluidcommunication with said cyclonic chamber outlet and a suction airflowoutlet; a main filter assembly located between said cyclonic airflowchamber and said suction source for filtering residual dust and dirtfrom a suction airstream as it flows through said cyclonic airflow dustand dirt separating chamber; and, wherein an inlet of said suctionsource is colinear with said cyclonic chamber outlet.
 10. The uprightvacuum cleaner as set forth in claim 9 further comprising a final filterassembly located on one of said housing and said nozzle base, said finalfilter assembly being in fluid communication with said suction airflowoutlet of said suction source for filtering said suction airstreamexhausted by said suction source prior to said suction airstream beingdispersed into the atmosphere and wherein said final filter assemblycomprises a high efficiency particulate arrest (HEPA) filter media. 11.The upright vacuum cleaner as set forth in claim 9 wherein said mainfilter assembly comprises a filter element including porous high-densitypolyethylene foam filter media.
 12. The upright vacuum cleaner as setforth in claim 11 wherein said porous filter media has pores with anaverage pore size of less than approximately 90 μm.
 13. The uprightvacuum cleaner as set forth in claim 9 further comprising a filter rackon which a main filter of said main filter assembly is mounted.
 14. Theupright vacuum cleaner as set forth in claim 9 further comprising a dirtcup, wherein said cyclonic airflow chamber is defined within said dirtcup and between an interior wall thereof and an exterior wall of saidmain filter assembly.
 15. A vacuum cleaner comprising:a nozzle section;a housing section connected to said nozzle section and in fluidcommunication with said nozzle section; a dirt cup selectively mountedin said housing section; a cyclonic airflow chamber located in said dirtcup for separating dirt and dust from a suction airstream flowing intosaid housing section between an inlet located adjacent a first end ofsaid housing section and an outlet located adjacent a second end of saidhousing section; a filter assembly located in said dirt cup, said filterassembly comprising:a filter rack, and a first filter element mounted onsaid filter rack.
 16. The vacuum cleaner as set forth in claim 15further comprising a suction source having an inlet located directlybeneath said outlet of said housing section.
 17. The vacuum cleaner asset forth in claim 15 wherein said inlet of said housing section islocated on a periphery of said dirt cup and said outlet of said housingsection is located along a longitudinal axis of said dirt cup.
 18. Thevacuum cleaner as set forth in claim 15 wherein said first filterelement comprises high density polyethylene porous filter media havingan average pore size of approximately 45 μm to approximately 90 μm. 19.The vacuum cleaner as set forth in claim 15 further comprising a lid forselectively covering said dirt cup.
 20. The vacuum cleaner as set forthin claim 16 further comprising a second filter chamber disposed betweensaid outlet of said housing section and said inlet of said suctionsource and a second filter element housed in said second filter chamber,for filtering contaminants from said airstream exhausted from saidhousing section.